Roll Eccentricity Monitoring Using Position-Based Force Averaging
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Solution Overview
Problem
Existing roll state monitoring systems suffer from accuracy deterioration due to noise in rolling force sensor outputs, leading to incorrect identification of roll eccentricity and state determination, which results in false alarms and reduced determination accuracy.
Innovation Solution
A roll state monitor device that detects rolling force variations across multiple rotation positions, calculates representative values for normal roll eccentricity, and uses statistical methods to determine the roll state by comparing current eccentricity values with pre-defined criteria, thereby reducing the influence of abnormal values and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If one rolling force detection value is used to calculate identification value or determine roll state, then the device complexity is reduced, but the measurement precision deteriorates due to noise and abnormal values
Solution Approach 1:
The patent segments the rolling force detection data by dividing it into multiple detection values corresponding to different rotation positions of the roll. Instead of using a single detection value, the system collects multiple values (e.g., 4-16 values per rotation) and processes them separately to identify roll eccentricity, thereby improving measurement precision without significantly increasing system complexity
Solution Approach 2:
The patent applies preliminary filtering and averaging actions to the detected rolling force values before using them for roll state determination. By pre-processing the data to remove noise and abnormal values through averaging multiple detections, the system maintains high identification accuracy while keeping the overall device complexity manageable
2Measurement precision
If multiple rolling force detection values are collected and processed, then the measurement precision of roll eccentricity identification is improved, but the device complexity increases
Solution Approach 1:
The patent implements periodic detection by collecting rolling force values at specific rotation positions (e.g., every 90 degrees or at 4-16 equidistant positions) during each roll rotation. This periodic sampling approach improves measurement precision by capturing the eccentricity pattern systematically, while the regular interval makes the data processing more manageable and less complex
Solution Approach 2:
The patent uses multiple copies of detection values obtained from different rotation positions to represent the same roll eccentricity condition. By collecting equivalent information through multiple measurements and using averaging or statistical methods, the system achieves higher precision without requiring complex processing algorithms
3Productivity
If abnormal values due to noise are included in roll state determination, then the productivity is maintained by continuous monitoring, but the reliability deteriorates due to false alarms
Solution Approach 1:
The patent implements feedback mechanisms by continuously comparing detected rolling force values against established patterns and thresholds. The system uses feedback from multiple detection cycles to identify abnormal values and adjusts the determination process accordingly, maintaining continuous monitoring while improving reliability by filtering out false alarms caused by noise
Solution Approach 2:
The patent changes the parameter of determination by using statistical parameters (such as average value, standard deviation) derived from multiple detection values instead of relying on single absolute threshold comparisons. This approach allows continuous monitoring to maintain productivity while the statistical analysis improves reliability by reducing the impact of abnormal values and noise
Data Source
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AI summary
A roll state monitor device includes: rolling force detecting means configured to detect rolling force of a monitored roll selected from an upper roll set and a lower roll set when a rolled material is rolled between the upper roll set and the lower roll set, the upper roll set having at least one roll and the lower roll set having at least one roll; force variation value extracting means configured to extract a rolling force variation value based on the rolling force for each rotation position of the monitored roll; and identification means configured to identify a roll eccentricity amount of the monitored roll by acquiring a plurality of accumulated values by accumulating separately for each rotation position of the monitored roll a value which is one of the rolling force variation value and a roll gap equivalent value calculated based on the rolling force variation value, and by dividing each of the plurality of accumulated values by a correction coefficient corresponding to a roll rotation amount which is number of times the monitored roll is rotated in an accumulation period in which the plurality of accumulated values are acquired.